cbb2093 (2) standards regulations

7/28/2019 CBB2093 (2) Standards Regulations

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CHAPTER 2CHAPTER 2

Process SafetyProcess Safety--RelatedRelatedStandards & RegulationsStandards & Regulations

Instructional Learning ObjectivesInstructional Learning Objectives

After completing this chapter, students should be able toAfter completing this chapter, students should be able todo the followin :do the followin :

Brief understanding of safety regulations:Brief understanding of safety regulations:

•• OSHA (Occupational Safety and Health Act) Process SafetyOSHA (Occupational Safety and Health Act) Process SafetyManagement StandardManagement Standard

•• Factory and Machinery’s ActFactory and Machinery’s Act

•• Other International Safety Legislations: CIMAH, COMAH,Other International Safety Legislations: CIMAH, COMAH,COSHHCOSHH

CAB2093CAB2093 Chapter 2: ProfessChapter 2: Profess--Safety RelatedSafety RelatedStandards & regulationsStandards & regulations

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Relate the standards and regulations’ requirementsRelate the standards and regulations’ requirementswith the application of process safety fundamental towith the application of process safety fundamental toprevent lossesprevent losses



PSM BackgroundPSM Background -- FlixboroughFlixborough 7474

Caprolactam Plant Explosion

Poorly engineered temporary

plant modifications

Control building collapsed,killing 28 operators

Outcomes

–Led to Advisory Committeeon Ma or Hazards


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–HSE champions Safety Report

concept –Led ultimately to CEC Seveso

Directive / Safety ReportConcept

PSM Background - Pasadena 1989

Plastics Manufacture PlantFire following vapour cloudexp os on

Poor Maintenance procedures,Contractor control andManagement of change

23 Fatalities132 InjuredUS$1,400 Million Damage


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Outcomes

–US OSHA PSM regulations

–CCPS established



Impact of Standards and RegulationsImpact of Standards and Regulations

Laws and regulations are major tools for protecting peopleLaws and regulations are major tools for protecting peopleand the environmentand the environment

Government is responsible to create and enforceGovernment is responsible to create and enforceregulationsregulations

Major government agencies involved in creating andMajor government agencies involved in creating andenforcing safetyenforcing safety--related standards and regulations:related standards and regulations:•• Department of Safety and Health (DOSH)Department of Safety and Health (DOSH)

•• Department of Environment (DOE)Department of Environment (DOE)


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•• a ona ns ue o ccupa ona ae y an eaa ona ns u e o ccupa ona a e y an ea

Occupational Safety and Health Acts of 1970 (OSHA)Occupational Safety and Health Acts of 1970 (OSHA)

OSHA is used for Process Safety Management of HighlyOSHA is used for Process Safety Management of HighlyHazardous ChemicalsHazardous Chemicals

ObjectiveObjective: prevent unwanted releases of hazardous chemicals: prevent unwanted releases of hazardous chemicalsespecially into locations that could expose employees and others toespecially into locations that could expose employees and others toserious hazardsserious hazards

Makes employers responsible for providing safe and healthy workingMakes employers responsible for providing safe and healthy workingconditions for employeesconditions for employees

Highlights of OSHA’s enforcement rights:Highlights of OSHA’s enforcement rights:

•• Employers must admit OSHA compliance officers into their plant sites forEmployers must admit OSHA compliance officers into their plant sites for


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..

required to show probable causerequired to show probable cause•• OSHA’s right of inspection includes safety and health recordsOSHA’s right of inspection includes safety and health records

•• Criminal penalties can be invokedCriminal penalties can be invoked

•• OSHA officers finding conditions of imminent danger may request plantOSHA officers finding conditions of imminent danger may request plantshutdownsshutdowns




OSHA incidence rate is based on cases per 100 workers years.

A worker year is assumed to contain 2000 hours

(50 work weeks x 40 hours/week)

The OSHA incidence rate is based on 200,000 hours exposure

to a hazard

OSHA incidence rate Number of injuries and

(based on injuries = illnesses x 200000


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Total hours w orked by all

employees during period

covered.


OSHA incidence rate Number of Los t

(based on lost = workdays x 200,000

workdays)

Total hours worked by all

employees during period


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covered.



Factories and Machinery Act (FMA), 1967Factories and Machinery Act (FMA), 1967

Provides equal protection for all workers working inProvides equal protection for all workers working infactories in terms of health and safety regardless of sexfactories in terms of health and safety regardless of sex

Examples of FMA’s enforcement rights:Examples of FMA’s enforcement rights:•• specify duty of occupier to provide rest rooms for womenspecify duty of occupier to provide rest rooms for women•• only a male person of at least 20 years of age may carry outonly a male person of at least 20 years of age may carry out

examination, lubrication or adjustment of unfenced machineryexamination, lubrication or adjustment of unfenced machinerywhile it is in motionwhile it is in motion

•• pregnant or breastfeeding workers must be temporarily removedpregnant or breastfeeding workers must be temporarily removedfrom leadfrom lead--processing areasprocessing areas

•• details for the reinstatement of the worker once she is no longerdetails for the reinstatement of the worker once she is no longer


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pregnan or reas ee ngpregnan or reas ee ng

Other International Safety Legislations:Other International Safety Legislations:

CIMAH, COMAH, COSHHCIMAH, COMAH, COSHH

Control of Industrial Major Accident Hazards (CIMAH)Re ulations 1984 UK has been re laced b Control of Major Accident Hazards Regulations 1999 (COMAH)

Control of Substances Hazardous to Health (COSSH)


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Control of Industrial Major Accident HazardsControl of Industrial Major Accident Hazards

(CIMAH) Regulations, 1984(CIMAH) Regulations, 1984

CIMAH was prompted by a number of serious accidents• Flixborou h, UK (1974) – c clohexane release

• Beek, Holland (1975) – petroleum refinery fire

• Seveso, Italy (1976) – toxic release

Aimed to control major accidents by:

• identification (of hazardous installations)

• prevention (of hazards)

• mitigation (of effects of hazards)


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3 elements of controlling major industrial accidents:

• identification (e.g., through NIHHS Regulations in UK)• control of location of hazardous installations

• assessment of hazards

Control of Major Accident Hazards Regulations1999 (COMAH)

Aim: to improve effectiveness of CIMAH

• CIMAH emphasized technical safety but management error isresponsible for 90% of major accidents

• COMAH emphasizes management errors

Changes implemented in COMAH:

• Major Accident Prevention Plan (MAPP) introduced inCOMAH—must include:


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aims of processing activities

principles of hazard control

description safety management systems (SMS)



Control of Major Accident Hazards Regulations1999 (COMAH)

Changes implemented in COMAH (continued):

•

Must fully address potential hazards

Must be submitted to “competent authority (i.e., HSE in UK)

Management and organizational issues must be considered

• Site and installation: provisions apply to whole site as well asindividual installations (plants)

• Domino effects: effects of an incident on surrounding plants must


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• Emergency plans must be included

Control of Substances Hazardous to Health(COSHH) Regulations, 2002

Main piece of legislation covering control of the risks toem lo ees and other eo le arisin fromex osure to harmful substances generated out of or in connection withany work activity under the employer's control

Main objective: to reduce occupational ill health bysettingout a simple framework for controlling hazardoussubstances in the workplace


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Control of Substances Hazardous to Health(COSHH) Regulations, 2002

Many of the chemicals found in the process industries are

Examples of harmful effects:

• skin contact→ dermatitis

• allergic reactions→ asthma

• toxic fumes→ losing consciousness

• chemical exposure→ cancer


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substances

COSHH provides hierarchy of measures to controlexposure

COSHHCOSHH (continued

)Hierarchy of Measures to Control Exposure

1. Assess risks to health

.

3. Where prevention is not reasonably practicable, decidewhat steps will achieve adequate control of exposure

4. Ensure control measures are used and maintainedproperly

5. Monitor exposure of employees if necessary


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6. Carry out health surveillance where assessment hasshown this to be necessary

7. Ensure employees are properly informed, trained, andsupervised

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